Singulation and separation system for a shrimp processor

ABSTRACT

A separation and singulation system for presenting shrimps or other product individually to a processor. The separation and singulation system includes a divider pan that separates a layer of shrimp into several lanes, a shaker pan that receives the lanes of shrimp and agitates them to separate clumps of shrimp and a flume for providing further singulation and acceleration of the shrimp. The singulated, separated shrimps are then sent to a processor.

RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 17/499,093, filed Oct. 12, 2021, and entitled “Singulation andSeparation System for a Shrimp Processor”, which is a continuation ofU.S. patent application Ser. No. 16/639,648, filed Feb. 17, 2020, andentitled “Singulation and Separation System for a Shrimp Processor”,which is a § 371 application of PCT/US2018/049323, which claims priorityto U.S. Provisional Patent Application Ser. No. 62/554,190, filed Sep.5, 2017, entitled “Singulation and Separation System for a ShrimpProcessor”, the contents of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION

The invention relates generally to shrimp processing, in particular thesingulating and separating of shrimp before subsequent processing.

Shrimp processors sort shrimp by weight because larger shrimp can besold at a higher price than smaller shrimp. Grading, sorting or otherprocessing systems may require shrimp to be singulated and separatedprior to processing. Because shrimps, especially peeled shrimps, are wetand somewhat sticky, they tend to adhere to each other. Touching orpiggy-backed shrimps can cause problems for subsequent processes, suchas vision grading. Other products may also require separation andsingulation prior to a process, such as grading.

SUMMARY OF THE INVENTION

One version of an apparatus embodying features of the invention forseparation and singulating a batch of a product comprises a divider panthat separates a layer of product into several lanes of product, ashaker pan that receives the lanes of product and agitates them toseparate clumps of product and a flume for providing further singulationand acceleration of the individual product. The singulated, separatedobjects are then sent to a processor, such as a grader.

According to one aspect, an apparatus for singulating a batch of aproduct comprises a conveyor for conveying the product, a divider panpositioned below an outfeed end of the conveyor for receiving theproduct and dividing the product into a plurality of lanes of productand a plurality of flumes positioned to receive the plurality of lanesof product. The flumes provide a flow of water to accelerate the productto separate and singulate the product.

According to another aspect, an apparatus for singulating a batch of aproduct comprises a conveyor for conveying the product, a divider panpositioned below an outfeed end of the conveyor for receiving theproduct and dividing the product into a plurality of lanes of productand a plurality of flumes positioned to receive the plurality of lanesof product. The flumes accelerate the product to separate and singulatethe product. The divider pan comprises an angled back wall, a pluralityof upper dividing walls on the angled back wall forming upper channelsand a plurality of lower dividing walls below the upper dividing wallsforming lower channels.

According to another aspect, an apparatus for singulating a batch of aproduct comprises a conveyor for conveying the product, a divider panpositioned below an outfeed end of the conveyor for receiving theproduct and dividing the product into a plurality of lanes of productsand a plurality of flumes positioned to receive the plurality of lanesof product. Each flume comprises a first channel extending downwards andhaving a water nozzle forming a back wall of the first channel providinga fluid to carry the product.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a shrimp processing system including asingulation and separation section according to an embodiment of theinvention;

FIG. 2 is a close-up view of the singulation and separation section ofthe system of FIG. 1 ;

FIG. 3 is another view of the singulation and separation section of thesystem of FIG. 2 ;

FIG. 4 is an isometric view of a divider pan in the system of FIG. 1 ;

FIG. 5 is a front view of the divider pan of FIG. 4 ;

FIG. 6 is another view of the divider pan of FIG. 4 ;

FIG. 7 is an isometric view of the shaker pan in the system of FIG. 1 ;

FIG. 8 is a side view of the shaker pan of FIG. 7 ;

FIG. 9 is an end view of the shaker pan of FIG. 7 ;

FIG. 10 is an isometric view of the shaker pan and divider pancombination;

FIG. 11 is a front view of the combination of FIG. 10 ;

FIG. 12 is an isometric view of a flume channel of FIG. 1 ;

FIG. 13 is a side view of the flume channel of FIG. 12 ;

FIG. 14 is a front view of the flume channel of FIG. 12 ;

FIG. 15 is a front view of a nozzle in the flume channel of FIG. 12 ;

FIG. 16 is an isometric view of the nozzle of FIG. 15 ;

FIG. 17 is an isometric view of the nozzle and a portion of the flumechannel according to an embodiment of the invention;

FIG. 18 is a side view of a dewatering belt and water trap in the systemof FIG. 1 .

DETAILED DESCRIPTION

The invention will be described below relative to certain illustrativeembodiments, though the invention is not limited to the illustrativeembodiments. For example, the separation and singulation system is notlimited to shrimp, but can be used to separate and singulate anysuitable product prior to further processing.

A shrimp processing system embodying features of the invention is shownin FIG. 1 . A shrimp singulation and separation portion of the overallsystem is shown in FIGS. 2 and 3 . The illustrative shrimp processingsystem 10 includes a bulk feed tank 12 for holding a batch of shrimp orother product to be processed. A flighted, inclined conveyor belt 20pulls shrimp out of the bulk feed tank 12. The shrimp fall off theoutfeed end of the flighted, inclined conveyor belt into a secondaryfeed tank 30, which distributes shrimp on an inclined conveyor belt 36to prepare for singulation.

The secondary feed tank 30 may include an oscillating paddle 32 and aplunging paddle 34 to facilitate the distribution of a single layer ofshrimp on the inclined conveyor belt 36. The inclined conveyor belt 36may be inclined at any suitable angle, preferably between about 10° andabout 20° from horizontal, though the invention is not so limited. Anexample of an oscillating paddle 32 can be found in U.S. Pat. No.RE34646, the contents of which are herein incorporated by reference. Anexample of a suitable plunging paddle 34 can be found in U.S. Pat. No.9,132,969, the contents of which are herein incorporated by reference.The oscillating paddle 32 creates a wave-like motion to spread theproduct out onto the inclined conveyor belt 36, while the plungingpaddle 34 creates a single, even layer of the product on the inclinedconveyor belt 36.

From the secondary feed tank 30, the inclined conveyor belt 36 deliversthe evenly-distributed shrimp (or other product) to a divider pan 40,which divides the layer of shrimp into several lanes of shrimp. A shakerpan 50 receives the divided shrimp and spreads the shrimp out at asteady feeding rate.

The shaker pan 50 delivers the divided and spread-out shrimp into anarray of flumes 70, which further singulate and separate the shrimpbefore passing the shrimp onto an optional dewatering conveyor 90. Thedewatering conveyor 90 drains water from the shrimp and transfers thesingulated, separated and dewatered shrimp to a processor, which in theillustrative embodiment, is a visioning system for grading the shrimp,but the invention not so limited.

The illustrative visioning station 100 captures images of each shrimpand digitizes the images into digital images of each shrimp. In theillustrative embodiment, the visioning system 100 is used for gradingthe shrimp in a subsequent grading station 102, though the invention isnot limited to the illustrative process.

Referring to FIGS. 4-6 , the divider pan 40, which may be formed ofsheet metal or another suitable material, includes a back wall 41extending down from the outfeed end of the secondary feed tank 30. Theillustrative back wall 41 extends from the outfeed end of the inclinedconveyor belt 36 of the secondary feed tank 30 at an angle of between10° and about 20° from vertical, though the invention is not so limited.The divider pan 40 includes upper dividing walls 42 a-42 f extendingfrom a front face of the back wall 41 forming diverging channels 45 a-fand lower dividing walls 46 a-b and 44 a-j forming converging channels48 a-f.

The upper dividing walls 42 a-42 f fan out, with central upper dividingwalls 42 c and 42 d converging to a central top point 49. The upperdividing walls 42 a-42 f may manually be adjustable using mounting slots401 in the back wall 41 and fasteners 402 at the top and-or bottom ofone or more of the upper dividing walls. The fasteners 402 may beloosened and slid to a select position in the mounting slot 401, thentightened to set the position of the associated upper dividing wall. Anysuitable means for adjusting the walls may be used and the invention isnot limited to the illustrative embodiment.

The lower dividing walls include angled edge walls 46 a, 46 b that slantdown and towards the middle of the plate and angled middle walls 44 a-44j that alternate in orientation. Adjacent middle walls converge at toppoints 47 to form A-frame channel dividers defining the sides of theconverging channels 48. Falling shrimp from an upper diverging channel45 is directed into a converging channel 48 below. Any suitable meansfor forming the converging channels 48 may be used, and the invention isnot limited to the illustrative structures. In the illustrativeembodiment, the lower edges of the upper dividing walls 42 extend intothe lower converging channels 48, but the invention is not so limited.

From the lower converging channels 48, the shrimp fall into associatedchannels of the shaker pan 50.

A rounded guide bar 43 tops each upper dividing wall 42, with middlewalls 42 c, 42 d sharing a rounded guide bar 43. The rounded guide bars43 extend down at an angle of between about 30° and about 50° andpreferably between about 35° and about 45° from horizontal to preventproduct from becoming stuck as it tumbles from the secondary feed tank30.

Preferably, the divider pan 40 is formed of a low-friction material,such as a dimpled or quilted metal. An example of a suitable material isRimex type 7GM® material, though the invention is not limited. Thematerial can be coated in Teflon® or another similar material to furtherreduce friction.

The illustrative divider pan 40 evenly divides product into multipleindependent lanes at a steady flow rate. Product is directed from thelower channels 48 into the shaker pan 50.

Referring to FIGS. 7-11 , the shaker pan 50 receives shrimp from thelower channels 48 of divider pan 40 and agitates the shrimp to declumpthem, shaking the product one-by-one onto the flumes 70. Theillustrative shaker pan comprises six channels 51 a-f, each positionedto receive product from an aligned divider pan lower channel 48, asshown in FIGS. 10 and 11 . Each shaker pan channel 51 comprises asubstantially flat bottom extending downwards at an angle of betweenabout 5° and about 20° from horizontal, though the invention is not solimited. The side walls of the channels 51 slant outwards and widentowards the top. The shaker pan 50 includes flexible connectors 52 formounting the channels 51 to a frame. The illustrative connectors 52 areabove the channels 51, but the invention is not so limited. For example,the connectors could be below the channels or have another configurationand-or location.

An actuator shakes the channels 51 a-51 f to separate shrimp travelingthrough the channels. The illustrative actuator comprises a motor 60that rotates a shaft 61. The shaft 61 passes through shaft supports 62.Shaft-channel connectors 63 connects the shaft 61 to the channels 51 totranslate motion of the shaft 61 to shaking of the channels 51. Eachshaft-channel connector 63 includes an opening at a first end forreceiving the shaft 61 and an opening at a second end that connects to abracket 64 mounted to the bottom of an associated channel 51. When themotor 60 rotates the shaft 61, the connectors 63 translate the motioninto a shaking action on the shaker pan.

The illustrative shaker pan 50 is inherently balanced. For example, inone embodiment, each shaft-channel connector 63 includes an eccentric 65rotatably mounted in the first end opening of the connector 63. Theeccentric 65 includes an opening that receives the shaft 61 to connectthe shaft 61 to the bracket 64. The shaft opening is offset from thecenter of the eccentric to cause the connector end to move in a circuitwhen the shaft 61 is rotated by the motor 60. Each eccentric opening isout-of-phase with the opening of an adjacent eccentric. In oneembodiment, first and second eccentrics, associated with connectors 63a, 63 b, are 180° out of phase with each other and cancel each otherout. A third eccentric, associated with connector 63 c, is offset fromthe second eccentric by 60°, with a fourth eccentric, associated withconnector 63 d, 180° out of phase with the third eccentric, canceling itout. A fifth eccentric, associated with connector 63 e, is 60° offsetfrom the fourth eccentric, and a sixth eccentric, associated withconnector 63 f, is offset from the fifth eccentric by 180°, canceling itout. This or any other suitable configuration can be used to minimizeperturbations.

The shaker pan 50 is designed to shake separated shrimp from eachchannel 51 onto an associated flume. The end of each channel 51 includesan open bottom that forms a funnel 59 over a top section of anassociated flume channel 70 to drop each shrimp onto a flume channel.

The shaker pan 50 is not limited to separate channels, and can comprisean open pan, or another suitable configuration.

Preferably, the shaker pan 50 channels are formed of a low-frictionmaterial, such as a dimpled or quilted metal. An example of a suitablematerial is Rimex type 7GM® material, though the invention is notlimited. The material can be coated in Teflon® or another similarmaterial to further reduce friction.

FIGS. 12-14 show an embodiment of a flume channel 70 suitable forreceiving shrimp or other product from a funnel 59 of the shaker pan 50or other source, and further singulating the shrimp. Each flumecomprises a first, upper flume 71, a second, middle flume 72, a third,lower flume 73 and a narrowing slide 74. The different sections can becoupled through fasteners or any suitable means.

The upper flume 71 slants downwards from the funnel 59 at an angle ofbetween about 5° and about 20° and preferably about 10° from horizontal,and includes a flat bottom wall 102, angled lower side walls 104 thatflare out and up and vertical upper side walls 106, though the inventionis not so limited. The upper flume 71 is symmetrical about a center line108 that is half-way between the vertical upper side walls 106.

The upper flume 71 also includes a water nozzle 80 forming a back wallof the flume 71. The water nozzle 80 sprays water or another liquid at asuitable rate to provide a flow of water carrying the shrimp through theflume channel 70. In one embodiment, the nozzle 80 sprays water at arate of between about 8 and about 12 gallons per minute to feed thebottom of the upper flume 71, though the invention is not so limited.

The second flume 72 is positioned to receive product from the firstflume 71. The second flume 72 is offset from the first flume 71 tofacilitate further separation of shrimp, i.e., the nadir of the secondflume is laterally shifted relative to the nadir of the upper flume,causing the shrimp flowing in water to move to towards one side of theflume. The second flume 72 comprises vertical upper side walls 116 thatare wider than the vertical upper side walls 106 of the upper flume 71,a curved, concave wall 114 and an angled side wall 112 that intersectsthe curved, concave side wall to define the nadir 115 of the channel.The second flume 72 is asymmetric about the lateral center line 108 toforce shrimp flow towards one side 78 of the flume channel. Theillustrative second flume 72 is angled downwards at an angle of betweenabout 0° and about 15° and preferably about 5° from horizontal, thoughthe invention is not so limited.

The third flume 73 receives shrimp from the second flume 72 and shiftsthe flow of shrimp towards the second side 79 of the flume channel toprovide further separation of shrimp. The third flume 73 is larger thanthe second flume 72 and includes vertical upper side walls 126 that arewider than the second flume walls 116, a concave, curved wall 124 and anangled wall 126 that intersects the concave, curved wall 124 to definean offset nadir 125 of the channel. The third flume 73 is alsoasymmetric about the lateral center line 108 to force shrimp towards theopposite side from the second flume 72. The illustrative third flume 73is angled downwards at an angle of between about 0° and about 15° andpreferably about 5° from horizontal, though the invention is not solimited.

The tapering slide 74 is positioned at the outlet of the third flume 73to receive separated shrimp, accelerate them to provide furtherseparation, and deliver them to a dewatering belt. The tapering slide 74comprises a wide upper section 131 having a bottom wall 132 that isslightly convex, a first side wall 134 that is substantially straightand a second side wall 133 that may taper from an outer point alignedwith the outer wall of the third flume. A narrowing middle section 135comprises a bottom wall 136 that extends downwards at an angle that isbetween about 50° and about 60° and preferably about 55° from horizontaland a first side wall 137 aligned with side wall 134 and a second sidewall 138 that tapers to narrow the channel formed by the flume 70. Atthe bottom, the tapering slide 74 comprises a slightly convex portion139 that deposits shrimp onto the dewatering belt. The illustrativebottom portion 139 has a consistent width, with parallel, vertical sidewalls 141, but the invention is not so limited.

The illustrative narrowing slide 74 accelerates shrimp or other productreceived from the shaker pan 50 or other source to a rate of betweenabout 400 and about 500 feet per minute, though the invention is not solimited.

Preferably, the flume components are formed of a low-friction material,such as a dimpled or quilted metal. An example of a suitable material isRimex type 7GM® material, though the invention is not limited. Thematerial can be coated in Teflon® or another similar material to furtherreduce friction.

FIGS. 15-17 show an embodiment of a nozzle 80 suitable for producing awater spray used to separate and accelerate shrimp on a slide. Thenozzle 80 is placed at the back of the first, upper flume 71 andconnected to a water source. The nozzle 80 comprises a base 81 thatforms a back wall of the upper flume 71. A tail portion 82 includes oneor more openings 83 for connecting the nozzle 80 to the flume and athickened upper portion 84 has a bottom edge 85 that matches the profileof the upper flume so that the upper portion 84 sits on the flat bottomwall 102 and a portion of the angled side walls 104. A central opening86 is connected to a water source. A lip 87 extends partially into thefirst flume 71 to form a channel for directing water provided throughthe central opening 86. The nozzle 80 provides an even flow of water,spread out over the wall 102. Notches 88 in the lip 87 ensure an evenspread of water in the flume 71. The illustrative nozzle is not limitedto use in the singulation and separation system 10, but can be used inany system requiring an even spread of water in a channel.

In the illustrative embodiment, each flume 70 discharges separatedshrimp (or other singulated product) onto a dewatering conveyor.Separated, singulated product is conveyed on the dewatering conveyor inseveral lanes. Referring to FIG. 18 , the dewatering conveyor 90comprises a perforated belt designed to drain water from the productinto a tank 91 or other suitable container. The drained water can berecycled back to a water source feeding the water nozzle 80. Inaddition, the dewatering conveyor 90 includes a water trap 92 at anoutfeed end of the dewatering conveyor for deflecting water into thetank 91. The water trap 92 directs water carried with shrimp dischargedfrom the dewatering conveyor 90 into the tank 91. The water trap 92comprises a curved sheet 94 spaced from the outfeed end of thedewatering belt and separating the outfeed end of the dewatering belt 90from the infeed end of a processing conveyor 120. The water trap 92further comprises a slanting cover sheet 95 forming a bridge between theoutfeed end of the dewatering belt 90 and the processing conveyor 120.In one embodiment, the water trap 92 can be adjusted up and down foroptimization.

The system can further include a whisker trap for removing detachedwhiskers from the flow, which may become trapped by the cover 95. Thewhisker trap can include a nozzle at the outlet of the dewateringconveyor. The nozzle directs water or another fluid over the cover, indirections perpendicular to the direction of belt travel. A whiskerholder below the belt outfeed may hold whiskers released from the cover.

Singulated, separated and dewatered product then passes onto aprocessing conveyor 120, which is positioned below the outfeed of thedewatering conveyor 90 to catch product dispatched from the dewateringconveyor.

Although the separation and singulation system has been described indetail with reference to a few versions, other versions are possible.The scope of the claims is not meant to be limited to the details of theexemplary versions.

What is claimed is:
 1. An apparatus for singulating a batch of a productcomprising: a conveyor for conveying the product; a divider panpositioned below an outfeed end of the conveyor for receiving theproduct and dividing the product into a plurality of lanes of product;and a plurality of flumes positioned to receive the plurality of lanesof product, wherein the flumes provide a flow of water to accelerate theproduct to separate and singulate the product.
 2. The apparatus of claim1, wherein each flume comprises a channel with a water nozzle forming aback wall of the channel providing a fluid to carry the product.
 3. Theapparatus of claim 1, wherein each flume comprises: an upper flume forreceiving the product, a middle flume for directing product receivedfrom the upper flume to a first side, a lower flume for directingproduct from the middle flume to a second side, and a narrowing slidefor receiving product from the lower flume and accelerating the product.4. The apparatus of claim 3, wherein the upper flume comprises a flatbottom wall, angled lower side walls that flare out and up and verticalupper side walls.
 5. The apparatus of claim 4, wherein the middle flumecomprises vertical upper side walls that are wider than the verticalupper side walls of the upper flume, a curved, concave wall and anangled side wall that intersects the curved, concave side wall to definea nadir that is laterally shifted relative to a nadir of the upperflume.
 6. The apparatus of claim 3, wherein the lower flume comprisesvertical upper side walls that are wider than the vertical upper sidewalls of the middle flume, a curved, concave wall and an angled sidewall that intersects the curved, concave side wall to define a nadirthat is laterally shifted relative to a nadir of the middle flume. 7.The apparatus of claim 3, wherein the tapering slide comprises: a wideupper section having a convex bottom wall, a first side wall that issubstantially straight and a second side wall that tapers from an outerpoint aligned with an outer wall of the lower flume; a narrowing middlesection comprising a downwards angled bottom wall, third side wallaligned with the first side wall and a fourth side wall that tapers tonarrow the channel formed by the flume.
 8. The apparatus of claim 7,wherein the tapering slide further comprises a bottom section having aconvex bottom wall and parallel, vertical sides.
 9. The apparatus ofclaim 1, further comprising a dewatering conveyor for receivingseparated product from the plurality of flumes and draining water fromthe separated product.
 10. The apparatus of claim 1, further comprisinga shaker pan positioned to receive product from the divider pan, whereinthe shaker pan agitates the product to break apart any clumps of productbefore passing the product to the plurality of flumes.
 11. The apparatusof claim 1, wherein the divider pan comprises: an angled back wall; aplurality of upper dividing walls on the angled back wall forming upperchannels; and a plurality of lower dividing walls below the upperdividing walls forming lower channels.
 12. The apparatus of claim 11,wherein two of the angled lower dividing walls form an A-frame dividerhaving a peak that extends into an end of an upper channel.
 13. Anapparatus for singulating a batch of a product comprising: a conveyorfor conveying the product; a divider pan positioned below an outfeed endof the conveyor for receiving the product and dividing the product intoa plurality of lanes of product, the divider pan comprising an angledback wall; a plurality of upper dividing walls on the angled back wallforming upper channels; and a plurality of lower dividing walls belowthe upper dividing walls forming lower channels; and a plurality offlumes positioned to receive the plurality of lanes of product, whereinthe flumes accelerate the product to separate and singulate the product.14. The apparatus of claim 13, wherein two of the angled lower dividingwalls form an A-frame divider having a peak that extends into an end ofan upper channel.
 15. The apparatus of claim 13, wherein each flumecomprises a channel with a water nozzle forming a back wall of thechannel providing a fluid to carry the product.
 16. An apparatus forsingulating a batch of a product comprising: a conveyor for conveyingthe product; a divider pan positioned below an outfeed end of theconveyor for receiving the product and dividing the product into aplurality of lanes of product; and a plurality of flumes positioned toreceive the plurality of lanes of product, each flume comprising a firstchannel extending downwards and having a water nozzle forming a backwall of the first channel providing a fluid to carry the product. 17.The apparatus of claim 16, wherein each flume comprises a plurality ofoffset channels.
 18. The apparatus of claim 16, wherein a nozzlecomprises a base that forms a back wall of the first channel, a tailportion for connecting the nozzle to the flume and a thickened upperportion having a bottom edge that matches the profile of the firstchannel.
 19. The apparatus of claim 19, further comprising a wateropening connected to a water source and a lip extending partially intothe first channel for directing water provided through the wateropening.